Decorative laminate

ABSTRACT

A decorative laminate and method of manufacture therefor are provided wherein the laminate has a differential texture and a differential gloss wherein the textured regions contain PVC resin particles and have a lower gloss than adjoining regions without PVC resin particles. The decorative article is useful as a floor covering.

FIELD OF THE INVENTION

The present invention relates to decorative laminates that are suitableas surface coverings for floors, walls, etc., and, more particularly, isdirected to a decorative laminate having differential surface textureand differential surface gloss features.

BACKGROUND OF THE INVENTION

Generally speaking, decorative laminates useful as surface coverings forfloors are well-known in the art and have achieved broad use in bothdomestic and commercial environments. For example, decorative laminatesin the form of sheet material of a resinous polymer composition, e.g.,polyvinyl chloride, on a suitable substrate, e.g., a fibrous backingsheet, have been used for many years as sheet flooring. A goal common toall manufacturers of sheet flooring is to provide flooring productshaving appealing surface decorative effects that are both attractivefrom an aesthetic viewpoint and useful from a functional standpoint. Toillustrate, many methods and processes such as mechanical embossing,chemical embossing or inlaying have been utilized to provide contrastingsurface finishes and thereby impart decorative effects to the sheetflooring. For example, U.S. Pat. Nos. 3,000,754; 3,121,642 and 4,298,646each discloses different techniques or means for making floor coveringproducts such as floor tiles or sheet flooring having decorative surfaceeffects.

SUMMARY OF THE INVENTION

According to the present invention there is provided a decorativelaminate having differential surface texture and differential surfacegloss suitable as a floor covering comprising a substrate having aprinted image thereon; PVC resin particles adhered to said substrate inregister with said printed image; and a layer of transparent syntheticorganic polymer adhered to the surface of said PVC resin particles andthe portion of said substrate intermediate said PVC resin particles;whereby the regions of said decorative laminate overlying said PVC resinparticles exhibit a rougher surface texture and a lower gloss than theregions of said decorative laminate intermediate said PVC resinparticles.

According to the present invention there is further provided a methodfor making a decorative laminate having differential surface texture anddifferential surface gloss suitable as a floor covering, said methodcomprising applying to a substrate material a vinyl plastisol printingink composition in register with a printed image on said substrate;applying an excess of PVC resin particles over said vinyl plastisolprinting ink composition and the surface of said substrate and removingthe excess of said PVC resin particles that do not adhere to said vinylplastisol printing ink composition; heating said substrate to gel saidvinyl plastisol printing ink thereon and thereby firmly adhere said PVCresin particles to said vinyl plastisol printing ink; forming a topresinous layer on said PVC resin particles and the surface portion ofsaid substrate intermediate said PVC resin particles by applying atransparent synthetic organic polymer over said PVC resin particles andthe exposed surface of said substrate, and heating the resulting topresinous layer thereby to provide a fused decorative laminate, wherebythe regions of said decorative laminate overlying said PVC resinparticles exhibit a rougher surface texture and a lower gloss than theregions of said decorative laminate intermediate said PVC resinparticles.

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying drawings:

FIG. 1 is a cross-sectional view depicting the arrangement of elementsand structural features of the decorative laminate of the invention;

FIG. 2 is a cross-sectional view of another embodiment of the decorativelaminate of the invention having a transparent layer of polymericmaterial interposed between the printed substrate and the polyvinylchloride particles; and

FIG. 3 is a cross-sectional view of another embodiment of the decorativelaminate of the invention having a base layer of different constructionthan that shown in FIGS. 1 and 2.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIGS. 1 and 2, which disclose preferred embodiments, thedecorative laminate 10 of the invention comprises a substrate member 11which is often referred to as a base layer or backing sheet. Thesubstratemember or element 11 bears a printed image 12 on one surfacethereof. A layer 14 of vinyl plastisol printing ink is disposed inregister with the printed image 12 on substrate 11. Particles ofpolyvinyl chloride (PVC) 16are disposed on and secured to the layer 14of vinyl plastisol printing inkand are arranged or distributed inregister with the printed image 12 on substrate 11. A top layer 17 oftransparent synthetic organic polymeric material overlies both PVC resinparticles 16 and the regions above substrate 11 that are intermediatethe PVC resin particles. Layer 17 of laminate 10 is often referred to asa "wear layer" when the laminate is used as a floor covering. Thedecorative laminate of the invention as shown in FIG. 1 is of unitaryconstruction wherein the elements or components thereof describedhereinabove have been fused by heat in accordance with the methoddescribed hereinafter.

The decorative laminate 10 depicted in FIG. 2 differs from that shown inFIG. 1 by including a layer 13 of transparent synthetic organicpolymeric material which covers both printed image 12 and the surface ofsubstrate member 11 intermediate the printed image 12 thereon.Interrupted line 15 shown in FIG. 2 illustrates the top surface of layer13. In the embodimentof FIG. 2, the layer 14 of vinyl plastisol printingink is disposed on layer 13 in register with the printed image 12 onsubstrate 11.

The elements of decorative laminates 10 will be described individuallyherebelow in conjunction with a description of the method for combiningthese elements to make the decorative laminates.

The Substrate

The decorative laminate 10 is formed on a substrate or backing sheet 11of strong, durable and flexible material. The flexible backing can bewoven, felted or a solid sheet of synthetic or natural material. Theconventionalflexible backing is a web of felted fibers. The feltgenerally is produced using a Fourdrinier or cylinder paper machine withthe thickness of the resulting sheet being that usually used in floorand wall covering, that is, from 0.02 to 0.08 inch. A thickness of about0.032 inch is usually preferred. The fibrous material used is normallycellulose or asbestos in origin, although other fibers can be usedincluding those of mineral and animal origin. The sources of cellulosicmaterial can include cotton or other rag material, wood pulp includingboth ground wood and chemical woodpulp, paper, boxes, or mixturesthereof in any proportion. The web can alsocontain fillers, such as woodflour.

The felt can be strengthened and improved in water resistance byimpregnation with a bituminous material. Numerous bituminous materialsarewell-known as impregnants in the production of printed surfacecoverings and include asphalts of petroleum or natural origin and tarsand pitch residues of animal or vegetable origin. These materials can betreated to attain the desired physical properties of softening point orviscosity forsatisfactory use by such treatment as air blowing, steamdistillation and the like.

The impregnant should be uniformly dispersed throughout the felt sheet.This can be controlled to some extent by the saturating techniquethrough use of pressure rolls in the saturating bath. Where theimpregnant is not uniformly dispersed throughout, blistering canfrequently occur due to high concentrations of material adjacent to onesurface of the felt.

Other impregnants for the fibrous sheet can also be used to form backingsheets for use in the production of printed surface coverings inaccordance with the invention. Such materials as phenolformaldehyde andphenol-urea resins, polymerized vinyl compounds, such as polyvinylchloride, polyvinyl acetate and the like, cellulose acetate, cellulosenitrate, butadiene-styrene copolymer, butadiene acrylonitrile copolymer,natural rubber and the like can be used. Polymerizable materials canalso be incorporated into the felt and the sheet subjected to heat tocure and polymerize the material. Such materials as natural andsynthetic drying oils, mixtures of polyhydric alcohols and polybasicacids which cure to form polyesters, mixtures of polyhydric alcohols andpolyisocyanates whichcure to form urethane polymers, and the like can beused.

If an impregnated backing sheet is used, it usually is provided with oneormore seal coats prior to printing the decorative design. The sealcoats perform the desirable function of masking the color of the feltand preventing the impregnant from bleeding through and staining thewear layer and, in addition, create a smooth uniform surface suitable asa basefor printing. Felt sheets of the type commonly used as backingsfor printedsurface coverings tend to have minor surface irregularitiesdue to non-uniformities in the felt-making equipment. The sheet alsofrequently shows a number of small protruding lengths of fibers. Theseal coats are designed to hide all these irregularities. The totalthickness of seal coats required is normally from about 1 to about 12mils. This thickness can be created through use of a single thickcoating or several superimposed thinner coatings. Using the conventionaltechniques of coating, such as flexible doctor roller application, thedesired thicknessis created by use of more than one coating. The use ofmultiple coatings isalso desirable in promoting optimum adhesion of thewear surface layer to the backing, since the seal coat applied directlyto the fibrous backing can be designed for optimum sealing againstmigration of bituminous impregnant and the uppermost seal coat can bedesigned for optimum adhesion to the polyvinyl chloride surface wearlayer.

The seal coat is conveniently applied in the form of an aqueous emulsionofresinous binder and filler. In the preparation of the seal coat, aresinousbinder and filler are emulsified in water in the presence ofconventional wetting agents, thickening agents, anti-foam agents,sequestering agents and the like. After the application of the seal coatto the backing sheet,the coating is dried by subjecting the sheet toheat, as for example, in the range of about 100° F. to about 150° F. forabout 30 minutes to about 2 hours. Alternately, drying can be effectedby exposing the coated sheet to a temperature of 350° F. to 400° F. forabout 30 to about 300 seconds.

The resinous compound of the seal coat is preferably a vinyl resin.Suitable resins are commercially available in the form of aqueousdispersions containing from 40 to 50 percent solids, and vinyl resinplastisols and organosols. The dispersion can contain, in addition tothe plasticizer, resin, pigment and filler, conventional wetting agents,thickening agents, anti-foam agents, sequestering agents and alkali.Suitable wetting agents include the sodium salt of polymerized alkylaryl sulfonic acid, potassium oleate, alkyl aryl polyether sulfonate,resin acid soap and the like. Ammonium caseinate, borated casein, methylcellulose, carboxymethyl cellulose, hydroxyethyl cellulose and the likeare satisfactory thickening agents. Examples of suitable anti-foamagents are pine oil and silicone anti-foam agents, diglycol laurate, andoctyl alcohol. Suitable sequestering agents include tetrasodiumpyrophosphate and the tetrasodium salt of ethylenediamine tetra-aceticacid. The alkali provides a pH of about 7.0 so that there will be notendency for the latexto coagulate. Calcium hydroxide, sodium hydroxide,ammonia and potassium hydroxide are suitable alkalis for this purpose.

Normally, the pigments and fillers are ground with water in the presenceofwetting agents, thickening agents and the like and the pigmentdispersion is mixed with the vinyl resin and plasticizer later.Alternately, the sealcoat can be effectively applied in the form of asolution using, for example, a solvent such as toluene or methyl ethylketone. However, the cost of using solvent and the fire and healthhazards created by its use render the method undesirable.

The seal coat can contain stabilizers to retard the decomposition of thevinyl resin and increase the life of the product, such as sulfides andsulfites of aluminum, silver, calcium, cadmium, barium, sodium,magnesium,strontium; lead and tin stearates; oleates and othercomplexes; glycerine, leucine, alanine, o- and p-aminobenzoic andsulfanilic acids, hexamethylene tetramine, salts including phosphates,stearates, palmitates, oleates, ricinoleates, abietates, laurates,salicylates; and the like.

As stated hereinabove, the resin component of the seal coat ispreferably avinyl resin, that is, a polymeric material obtained bypolymerizing compounds containing at least one --CH═CH₂ radical. Usefulvinyl resins include homopolymers, such as polyvinyl chloride, polyvinylacetate, polyvinyl propionate, polyvinyl butyrate, polymerizedvinylidene chloride, polymerized acrylic acid, polymerized ethylacrylate, polymerized methyl acrylate, polymerized propyl acrylate,polymerized butyl acrylate, and the like; copolymers of the above witheach other suchas vinyl chloride-vinyl acetate copolymer, vinylidenechloride-vinyl chloride copolymer, methyl methacrylate-vinyl chloridecopolymer, methyl acrylate-ethyl acrylate copolymer, ethylacrylate-butyl acrylate copolymer, and the like and copolymers of theabove with other monomers copolymerizable therewith, such as vinylesters, including vinyl bromide, vinyl fluoride, vinyl choroacetate,vinyl alkyl sulfonates, trichloroethylene and the like; vinyl etherssuch as vinyl ethyl ether, vinyl isopropyl ether, vinyl chloroethylether and the like; cyclic unsaturated compounds such as styrene,chlorostyrene, coumarone, vinyl pyridine and the like; maleic andfumaric acid and their derivatives such as diethyl maleate, dibutylfumarate and the like; unsaturated hydrocarbonsuch as ethylene,propylene, butylene and the like; allyl compounds such asallyl acetate,allyl chloride, allyl ethyl ether, and the like; conjugated andcross-conjugated unsaturated compounds such as butadiene, isoprene,chloroprene, 2,3-dimethylbutadiene-1,3, divinyl ketone and the like. Themonomers listed hereinabove are useful in preparing copolymers with avinyl resin and can be used as modifiers in the polymerization, in whichcase they may be present in an amount of a few percent, or they can beused in larger quantities, up to as high as 40 percent by weight of themixture to be polymerized. If desired, a mixture of vinyl resins can beused in preparing coating paints for use in the invention.

A plasticizer for the vinyl resin is also frequently present in the sealcoat composition. Suitable plasticizers for the vinyl resin includeester type plasticizers such as tributyl phosphate, dioctyl phthalate,dipropylene glycol dibenzoate, phenyl phosphate, dibutyl tartrate, amyltartrate, butyl benzyl benzoate, dibutyl sebacate, dioctyl adipate,didecyl adipate and the like, rubbery plasticizers, such asbutadiene-styrene copolymer, butadiene-acrylonitrile copolymer, and thelike, and other materials which function as plasticizers, such asepoxidized drying oils, aromatic hydrocarbon condensates and the like.Where certain flexible soft vinyl resins are used in formulating theseal coat, such as polymers containing large proportions of ethylacrylate, no plasticizer is needed. However, in most instances, aplasticizer is essential in order to impart the necessary properties offlexibility to the dried seal coat film. The seal coat must becompatible with the subsequently applied layer.

Likewise, plastisol or organosol dispersions of vinyl resins can beutilized for seal coats on one or both surfaces of substrate 11.

The thickness of the relatively flat, fibrous substrate 11 will dependto alarge extent upon the particular product to be made and theparticular subsequent use for which it is intended. Normally, athickness in the range of from about 10 mils to about 90 mils issatisfactory.

The substrate 11 of FIGS. 1 and 2 and substrate element 21 of FIG. 3 mayalso be a thin sheet or mat of glass fibers that is saturated orcompletely coated with a heat-cured polyvinyl chloride plastisol ororganosol. Glass fiber mats are readily available and are disclosed in,for example, U.S. Pat. Nos. 3,980,511; 4,018,647 and 4,234,379,including also German Patent Publication OS 2,605,879, and the manypatents that aredescribed in the aforementioned patents.

Printed Image on Substrate

A decorative printed image 12 is applied to the substate 11 on thecoated surface thereof after drying the coating. Printing isconventional and paints and inks normally used for application of adecorative design to a vinyl film or layer are used. The composition ispreferably formulated so that the binder of the ink contains anappreciable quantity of a vinyl resin. Suitable vinyl resins includevinyl chloride polymer, vinyl chloride-vinyl acetate copolymer, vinylchloride-vinyl propionate copolymer, vinyl butyrate polymer, vinylidenechloride polymer, vinylidenechloride-vinyl chloride copolymer,copolymers of vinyl chloride and vinylidene chloride with esters ofmaleic and fumaric acid, such as dimethyl, diethyl, and dibutyl maleateand fumarate, and the like. Extender resins, such as nitrocellulose oracrylic polymers, can be employed as a portion of the binder of the inkor paint.

The decorative printing composition contains pigments according to thecolors desired and is preferably formulated as a solution in the solventsuch as cyclohexanone, methyl ethyl ketone, methyl isobutyl ketone andthelike.

The decorative printing composition can be applied to the seal coatedsurface of the sheet in any way appropriate for producing the particulardecoration desired. Any of the rotary graphic art printing processes,suchas rotogravure, offset printing or lithography, can be used. Ifdesired, the design can be applied by conventional block printingtechnique.

Base Layer of Transparent Synthetic Organic Polymer

An optional base layer 13 of transparent synthetic organic polymericmaterial may be applied to printed substrate 11. The polymericcompositionof base layer 13 may be any of the known synthetic resinssuch as, for example, a polymer or copolymer of vinyl chloride or otherresins such as polyurethane (sufficiently dimensionally stable) anelastomer such as natural or synthetic rubber, etc. Although a polymeror copolymer of vinylchloride in the form of a plastisol is thepreferred and typical synthetic resin to be incorporated into the baseresinous polymer composition, many other resins are of equalapplicability, not only in plastisol form but also in organosol, latexor solvent form. The specific resin and its particular form of use as itis being utilized does not relate to the essence of the inventiveconcept and many other resins are set forth in the previously mentionedU.S. Patents.

The base layer 13 of resinous composition may be applied by a doctorblade,or roll coated, or poured, or cast, or otherwise applied or formedand adhered to the carrying sheet material, such as the fibrous backingsheet material 11, in a substantially uniform manner in a relativelyuniform thin coating by procedures well-known in the art. The thicknessof base resinous composition 13 as applied and still wet, is in therange of from about 1 mil to about 50 mils, or even more, if so desiredor required by its subsequent use.

The Gelling of the Base Resinous Composition

After the base layer 13 of resinous plastisol composition has beenapplied or formed on the carrying backing sheet material, it is thenheated under moderately gentle heat for a period of time of from about 1minute to about 4 minutes at an elevated temperature of from about 240°F. toabout 450° F., but more normally commercially from about 290°F. toabout 350° F., whereby the plastisol gels and firms so that itcan bemore easily handled and processed in subsequent operations. The elevatedtemperature, however, is not that sufficiently high as to cause blowingor foaming of the base resinous polymer composition.

The Vinyl Plastisol Adhesive Composition

The substrate 11 or, optionally, the gelled, base layer 13 of resinouscomposition, is printed or coated with a suitable printing inkcompositionor compositions 14 in the desired or required pattern ordesign in registerwith the printed image 12 on substrate 11. Theparticular pattern or designwhich is used does not relate to the essenceof the invention and any suitable pattern or design may be selected. Theprinting procedure, in general, is conventional and should require nofurther description, inasmuch as such procedures are well known in theindustry and are described in many publications and patents.

The printed layer 14, preferably of vinyl plastisol, is approximately 3to 4 mils thick, although any desirable thickness may be utilized.Printed layer 14 is preferably applied to substrate 11 by means of arotary screen/blade coating device. The combination of a rotary screenprinter and a blade squeegee permits good control of the plastisol inkapplicationand allows the rotary screen to slip for achieving goodregistration of theink plastisol. In contrast, a rotary printing screenequipped with a rollersqueegee has not performed as satisfactorily andsuch combination is not recommended at this time.

Application of PVC Particles to the Printed Base Resinous Layer orSubstrate

Particles 16 of polyvinyl chloride (PVC) resin are applied to theprinting ink plastisol preferably by flooding the entire substrate 11 orthe base layer 13 and the printing ink layer 14 thereon with the PVCresin particles. The PVC resin particles 16 adhere to the printing ink14, and the excess PVC resin particles 16 that overlie the unprintedsurface portions of substrate 11 or base layer 13 are removed byappropriate means, e.g., air knife, vacuum or suction techniques anddevices.

The PVC resin particles 16 utilized for making the decorative laminateof the invention must be characterized by two essential features,namely, particle size and plasticizer absorption properties.Specifically, the PVCresin particles 16 must have a particle sizediameter of between about 4 mils and about 20 mils with, preferably, anaverage particle size diameterof between about 8 and about 12 mils.

Also, the PVC resin particles 16 must be classified as a Type GP resin(as specified in Table 1 of ASTM-D-1755) and characterized by aplasticizer absorption greater than about 40 grams per 100 grams of PVCresin (as measured by ASTM-D-3367, modified to allow a standing time of5 minutes instead of the 15 minutes specified in paragraph 7.6 of theASTM procedure). Satisfactory results in terms of differential gloss anddifferential texture have been achieved using G P resins having a cellclassification number of 4 (ASTM-D-1755).

PVC resin particles 16 having the foregoing particle size andplasticizer absorption properties are necessary in order to obtain thedesired differential gloss and differential texture features of thedecorative laminate of the present invention. Satisfactory results havebeen obtainedusing a particulate PVC resin sold under the tradenamedesignation "Geon 92" by the B. F. Goodrich Chemical Company, Inc.,Cleveland, Ohio. Particulate PVC resins that have not provided thedesired differential gloss and differential texture properties includeblending resins such a TENNECO 501 and Goodyear Pliovic M-70, anddispersion PVC resins such as TENNECO 1732 and TENNECO 1755.

The PVC resin particles 16 can be either clear, i.e. uncolored, orcolored.Suitably colored PVC resin particles 16 can be obtained bymixing clear PVCresin particles with dry opaque pigments with a suitableamount of plasticizer. The concentration of opaque pigment utilizedshould not be sohigh as to adversely affect the absorption property ofthe PVC resin particles, since otherwise, the absorption property of thePVC resin particles and the desired differential texture anddifferential gloss effect of the ultimate decorative laminate productare not obtained. Use of too large a quantity of plasticizer should beavoided when preparing colored PVC resin particles 16. Large quantitiesof plasticizer adversely affect the desired differential texture anddifferential gloss visual features of the finished laminate product(e.g., the finished laminate product will result in less surface textureand higher gloss). For example, the quantity of primary plasticizerwhich can be added to the PVCresin, such as Geon 92 as in Example 1should be less than about 30 phr.

Heating Printed Layer to Adhere PVC Resin Particles Thereto

The substrate 11 or the base layer 13 having the printed layer 14 withPVC resin particles 16 adhered to the plastisol ink of layer 14 isheated by conventional means, e.g., in a convection oven or by radiantheaters, to gel the plastisol and firmly adhere the PVC resin particlesthereto. Care must be exercised to avoid overheating the printed layer14 during the gelling sequence, since otherwise the PVC resin particles16 will absorb the printed plastisol 14 and not produce the desireddifferential gloss and differential texture effect in the final product.A suitable heating range is between about 250° F. and about 450° F.,preferably300° F.

Top Layer of Transparent Synthetic Organic Polymer

The substrate 11 or the base layer 13 having PVC resin particles 16selectively positioned thereon and adhered thereto is coated with a toplayer 17 of transparent, synthetic organic polymeric material such as,forexample, a polyvinyl chloride (PVC) plastisol. Preferably, thetransparent PVC plastisol has a viscosity of about 1000 centipoises andis applied to the intermediate laminate by means of a blotch rotaryscreen equipped witha blade squeegee. Suitable results have beenobtained with plastisols having a viscosity ranging between about 350and about 1250 centipoises. The combination of a blotch rotary screenprinter/blade coating device hasprovided better results to date thanother combinations of coating equipment or techniques, such as, forexample, a blade-over-roll, air knife, reverse roll or roller-typesqueegee and rotary screen coating techniques.

Use of plastisols having a viscosity much greater than about 1250centipoises is not recommended because the necessary quantity of theplastisol is difficult to control. Also, such plastisols have inadequateflow properties around and into the PVC resin particles 16. As a result,the desired differential gloss and differential texture features are notobtained in the final product.

The top layer 17 of the PVC plastisol extends over the entire surface ofthe intermediate decorative laminate so as to overlie both the PVC resinparticles 16 and the regions on the substrate 11 or base layer 13 thatareintermediate the PVC resin particles. Use of a rotary screenapplicator that is equipped with a blade squeegee device has permittedachievement ofa thin, uniform PVC plastisol coating on the PVC resinparticles which thoroughly saturates the region containing the PVC resinparticles while also coating the regions on substrate 11 or base layer13 that are intermediate the PVC resin particles.

Fusing the Top Resinous Composition

After the top layer 17 of resinous plastisol composition has beenapplied over the entire upper surface of the intermediate decorativelaminate, it is heated by conventional means, e.g., in a convection ovenor by radiant energy, at an elevated temperature to fuse the entireproduct and provide a product of unitary construction. Suitabletemperatures for heating top layer 17 include a range of between about350° F. and about 500° F., preferably 400° F.

As shown in FIGS. 1, 2 and 3, the resulting fused, decorative laminateis characterized by unique surface features comprising portions orregions 18that exhibit a rougher surface texture and have a low gloss,and regions 19that are smooth and have a high gloss. Also, the surfaceregions 18 that contain the PVC resin particles 16 have a greaterthickness than regions 19 thereby creating an embossed effect. Notably,the embossed effect of the decorative laminate is achieved withoutemploying secondary or additional measures such as chemical ormechanical treatment of the laminate. If desired, enhanced embossingeffects can be achieved by utilizing conventional chemical or mechanicalembossing techniques. For example, decorative vinyl flooring productshaving many different visual effects can be obtained by combining theforegoing techniques. For instance, a vinyl flooring product whichembodies the characteristic features of ceramic type floors can beobtained by placing the PVC resin particles in register with the printedportion 12 of substrate 20 that represents the grout lines of a ceramicor clay floor tile product. A foamable vinyl plastisol can be appliedover both the regions containing the PVC resin particles and the regionsadjacent thereto that do not contain the PVC resin particles. In thisinstance, a chemical inhibitor isapplied to the regions that contain thePVC resin particles, and the entireintermediate laminate is heated tofoam or expand the foamable plastisol layer thereby to achieve adecorative floor covering having a differentialprofile, i.e., anembossed surface, wherein the recessed portions representative of groutlines contain the PVC resin particles and have a low gloss. The raisedregions that are representative of the ceramic floortile surface do notcontain the PVC resin particles and have a smoother surface texture anda higher gloss than the recessed grout regions.

The surface texture of regions 18 is characterized by a surface profileof at least 50 micro-inches, root mean square (rms) and, preferably,between about 80 and about 1000 micro-inches (rms). The gloss oftextured regions 18 is characterized by a Gardner 60° gloss of less thanabout 30 gloss units, preferably below about 10 gloss units. Incontrast, the smooth and high gloss regions 19 are characterized by aGardner 60°gloss of greater than 30 gloss units, preferably betweenabout 50 and about100 gloss units, and most preferably about 80 glossunits.

The Embodiment of FIG. 3

The embodiment of the decorative laminate of the invention shown in FIG.3 is substantially the same as shown in FIGS. 1 and 2, except that thesubstrate layer 20 is of composite construction. Specifically, substratelayer 20 comprises a base member 21 of the same material as base member11of FIG. 1, and a base member 22 adhered to base member 21. Base member22 is of foamed resinous polymer such as blown or foamed polyvinylchloride.

The present invention is illustrated and described further in thefollowingExamples which are merely exemplary and which show typicalpreferred embodiments thereof. All parts and percentages in thefollowing Examples are by weight, unless otherwise specified.

The gloss and surface profile characteristics of the textured regions ofthe decorative laminates of the Examples were determined in accordancewith the following procedures:

Gloss measurement was obtained using a Gardner, Multi-Angle Glossmeter,Model No. GG9095 of Gardner Lab, Inc., Bethesda, Maryland, set at a 60°angle.

Patterns were selected to produce textured PVC particulate containingregions and smooth regions larger than 4"×4" squares in order to obtain60° gloss readings on each region independently.

Profile or surface topography of the raised, PVC particulate containingregions was characterized using a "Profilometer," MicrometricalManufacturing Company, Ann Arbor, Mich. The instrument was equipped witha0.0005 in radius diamond stylus and provided a direct readout in RMS(root mean square surface roughness) units that was an average valueobtained over a 0.030 inch scan of the sample. The "Profilometer" wascalibrated using a Stylus Radial Check standard of 9-13 RMS made byBendix Corporation, Automation & Measurement Division.

The samples were scanned at a rate of 0.1 inch per second and theaverage RMS value per inch sample scanned are reported in the Examples.

EXAMPLE 1

This example illustrates the decorative laminate of FIG. 2.

A foamable plastisol composition having the following formulation:

    ______________________________________                                        Formulation A                phr                                              ______________________________________                                        Vinyl chloride dispersion resin (Firestone FPC 605)                                                        72                                               Vinyl chloride blending resin (Goodyear Pliovic M70)                                                       28                                               Primary plasticizer (DOP)    45                                               Epoxy stabilizer (Drapex 4.4)                                                                              1.0                                              Zinc octoate                 1.4                                              ABFA blowing agent (Azo-bis formamide) Kempore AF                                                          2.5                                              ______________________________________                                    

was applied to a thickness of 8 mils onto an 0.032 inch gauge (thick)flooring felt backing and gelled at 320° F. for 1 minute in an airimpingement oven.

Thereafter, an image was rotogravure printed onto the above foamableplastisol layer.

Next, a transparent PVC plastisol layer of 5 mils thickness of thefollowing formulation:

    ______________________________________                                        Formulation B               phr                                               ______________________________________                                        Vinyl chloride dispersion resin (Tenneco (1755)                                                           90                                                Vinyl chloride blending resin (Borden 260 SS)                                                             10                                                Primary plasticizer (DOP)   25                                                Secondary plasticizer (TXIB-Texanol iso-butyrate)                                                         17                                                Epoxy stabilizer (Drapex 4.4)                                                                              3                                                Tin stabilizer (Mark 275)    1                                                ______________________________________                                    

was applied over the printed image and gelled at 320° F.

Next, approximately 4 mils of vinyl plastisol adhesive of the followingformulation:

    ______________________________________                                                                  phr                                                 ______________________________________                                        Vinyl chloride dispersion resin (Tenneco 1732)                                                            100                                               Primary plasticizer (DOP)   35                                                Secondary plasticizer (TXIB-Texanol iso-butyrate)                                                         17                                                Epoxy stabilizer (Drapex 4.4)                                                                              3                                                Tin stabilizer (Mark 275)    1                                                ______________________________________                                    

was applied using a rotary screen/blade coater in register with therotogravure printed design.

The resultant plastisol printed sheet was then flooded with Geon 92 PVCresin. The Geon 92 vinyl resin adhered to the printed plastisol. Theexcess resin was removed by dumping and the composite subsequentlygelled as described above.

The resultant gelled composite with raised regions containing Geon 92PVC resin was then overall clear coated using a blotch rotaryscreen/blade coater. A thin, uniform plastisol coating of Formulation Babove was applied on the surface of the Geon PVC particles. Under theseconditions, the entire surface of the composite is clear coated, but dueto raised Geon 92 containing regions, the thickness of the plastisolclear coat is different between the Geon 92 containing regions and theregions not containing the Geon 92 vinyl particles. The resultantcomposite was fused and expanded at 400° F. to provide a final producthaving raised surface textured lower gloss region containing Geon 92particles and higher gloss, smooth region. An approximately 5 milembossing was obtainedbetween regions.

The Gardner 60° Gloss of the texture region was measured and found to bebetween about 2 to 3 gloss units. In contrast, the Gardner 60° Gloss ofthe smooth regions was measured and found to be about 80 gloss units.

The surface profile of the textured regions was measured and found to beina range between about 50 and about 190 microinches (rms)--an averageof 120microinches (rms).

EXAMPLE 2

Instead of traditional flooring felt backing of Example 1, a vinyl/glasssheet composite backing can be utilized. For example, Schoeller 55/3glasssheet is completely saturated with the following foamable plastisolcomposition and the resultant composite gelled at 300° F.

    ______________________________________                                        Plastisol Saturant Formulation                                                                            phr                                               ______________________________________                                        Vinyl chloride dispersion resin (Firestone FPC605)                                                        67                                                Vinyl chloride blending resin (Goodyear Pliovic M70)                                                      33                                                Primary plasticizer (DOP)   36                                                Secondary plasticizer (TX1B)                                                                              21                                                Epoxy stabilizer (Drapex 4.4)                                                                             5                                                 Thermal stabilizer (Barium and Zinc Neodecanoate)                                                         1.7                                               ABFA blowing agent (Kempore AF)                                                                           0.9                                               ______________________________________                                    

An 8 mil coating of foamable plastisol was applied onto this glass/vinylcomposite, gelled and printed as in Example #1. The printed substratewas then processed as described in Example #1 to produce an embossedproduct with differential gloss and surface texture. If desired theresultant product can be back coated with a smoothing plastisol coat andheated to fully encapsulate the glass sheet in the final structure.

The surface profile of the textured regions of the product of Example 2wasmeasured and found to be in a range between about 50 and about 175micro-inches (rms)--an average of 110 micro-inches (rms).

What is claimed is:
 1. A decorative laminate having differential surfacetexture and differential gloss suitable as a floor covering comprisingasubstrate having a printed image thereon; PVC resin particles of type GPPVC resin adhered to said substrate in register with at least a portionof said printed image; and a layer of transparent synthetic organicpolymer adhered to the surface of said PVC resin particles and theportion of said substrate intermediate said PVC resin particles;wherebythe regions of said decorative laminate overlying said PVC resinparticles exhibit a rougher surface texture and a lower gloss than theregions of said decorative laminate intermediate said PVC resinparticles.
 2. The decorative laminate of claim 1 wherein the regions ofsaid laminate intermediate said PVC resin particles have a Gardner 60°gloss greater than about
 30. 3. The decorative laminate of claim 2wherein the textured regions of said laminate have a surface profile ofat least 50 micro-inches (rms).
 4. The decorative laminate of claim 2wherein said PVC resin particles have a particle size diameter betweenabout 4 mils and about 20 mils.
 5. The decorative laminate of claim 4wherein said PVC resin particles have a cell classification number of 4.6. The decorative laminate of claim 5 wherein said PVC resin particleshave a plasticizer absorption greater than about
 40. 7. The decorativelaminate of claim 6 wherein said PVC resin particles are pigmented. 8.The decorative laminate of claim 7 wherein said layer of transparentsynthetic organic polymer is polyvinyl chloride.
 9. The decorativelaminate of claim 1 wherein said substrate comprises a flexible basemember and a layer of a foamed polyvinyl chloride resin bonded to atleast one surface of said flexible base member.
 10. The decorativelaminate of claim 9 wherein said flexible base member is aresin-impregnated web of felted fibers.
 11. The decorative laminate ofclaim 10 wherein the regions of said laminate intermediate said PVCresin particles have a Gardner 60° gloss greater than about
 30. 12. Thedecorative laminate of claim 11 wherein the textured regions of saidlaminate have a surface profile of at least 50 micro-inches (rms). 13.The decorative laminate of claim 11 wherein said PVC resin particleshave a particle size diameter between about 4 mils and about 20 mils.14. The decorative laminate of claim 13 wherein said PVC resin particleshave a cell classification number of
 4. 15. The decorative laminate ofclaim 14 wherein said PVC resin particles have a plasticizer absorptiongreater than about
 40. 16. The decorative laminate of claim 15 whereinsaid PVC resin particles are pigmented.
 17. The decorative laminate ofclaim 16 wherein said layer of transparent synthetic organic polymer ispolyvinyl chloride.
 18. A decorative laminate having differentialsurface texture and differential gloss suitable as a floor coveringcomprisinga substrate having a printed image thereon; a first layer oftransparent PVC polymer overlying said printed image; PVC resinparticles of type GP PVC resin adhered to said first layer oftransparent PVC polymer in register with at least a portion of saidprinted image; and a second layer of transparent PVC polymer adhered tothe surface of said PVC resin particles and the portion of said firstlayer of transparent PVC polymer intermediate said PVC resin particlesthereon;whereby the regions of said decorative laminate overlying saidPVC resin particles exhibit a rougher surface texture and a lower glossthan the regions of said decorative laminate intermediate said PVC resinparticles.
 19. The decorative laminate of claim 18 wherein the regionsof said laminate intermediate said PVC resin particles have a Gardner60° gloss greater than about
 30. 20. The decorative laminate of claim 19wherein the textured regions of said laminate have a surface profile ofat least 50 micro-inches (rms).
 21. The decorative laminate of claim 19wherein said PVC resin particles have a particle size diameter betweenabout 4 mils and about 20 mils.
 22. The decorative laminate of claim 21wherein said PVC resin particles have a cell classification number of 4.23. The decorative laminate of claim 22 wherein said PVC resin particleshave a plasticizer absorption greater than about
 40. 24. The decorativelaminate of claim 23 wherein said PVC resin particles are pigmented. 25.The decorative laminate of claim 18 wherein said substrate comprises aflexible base member and a layer of a foamed polyvinyl chloride resinbonded to at least one surface of said flexible base member.
 26. Thedecorative laminate of claim 25 wherein said flexible base member is aresin-impregnated web of felted fibers.
 27. The decorative laminate ofclaim 26 wherein the regions of said laminate intermediate said PVCresin particles have a Gardner 60° gloss greater than about
 30. 28. Thedecorative laminate of claim 27 wherein the textured regions of saidlaminate have a surface profile of at least 50 micro-inches (rms). 29.The decorative laminate of claim 27 wherein said PVC resin particleshave a particle size diameter between about 4 mils and about 20 mils.30. The decorative laminate of claim 29 wherein said PVC resin particleshave a cell classification number of
 4. 31. The decorative laminate ofclaim 30 wherein said PVC resin particles have a plasticizer absorptionof greater than about
 40. 32. The decorative laminate of claim 31wherein said PVC resin particles are pigmented.